Unit dose articles and package therefor

ABSTRACT

A flexible sealed bag and method of making thereof; the flexible bag containing a plurality of at least partially water soluble unit dose articles comprises a front panel, a back panel and a bottom panel. The front panel and the back panel may be marginally joined together along at least two opposed edges to be in a confronting relationship to form the closed bag. The front and back panels are joined at the top of the bag by a frangible seal. The bottom panel is intermediate to the front panel and back panel, and is joined to each of them. The first panel comprises at least one transparent window and at least one opaque portion. The articles are distributed from the bottom of the bag to a height therein, providing an empty space above the height of the articles, whereby the transparent window intercepts the articles and the empty space.

FIELD OF THE INVENTION

The field of the present invention concerns packaging for unit dose articles, particularly unit dose articles comprising laundry compositions. The laundry compositions may include, but are not limited to, additives for use in wash and/or rinse cycles, detergents, fabric softeners, and perfumes among others. These unit dose articles may comprise compositions that are in any suitable form including, but not limited to, solids, pastes, gels, liquids and combinations thereof. Non-solid laundry compositions will most commonly be encapsulated in film material that is at least partially soluble in water.

BACKGROUND OF THE INVENTION

Life is becoming more hectic than ever. We now access global information at the touch of a button, keep our mobile phones handy for any eventuality, and as consumers, we have become accustomed to the get-it-now life style. Household compositions like detergents have been impacted by this trend. For example, over the last decade and a half manufacturers have moved from the traditional big-box laundry and auto dish detergents, to compacted detergents, and more recently, to unit dose detergents. The unit dose is typically a tablet or a water soluble pouch that can be directly added into a washing machine, without the bother or mess of measuring. The unit dose is designed to dissolve in the water during the wash cycle.

Water-soluble unit dose articles are susceptible to incidental or unintentional contact with moisture. Consequently, it is important to protect the article from moisture during the various stages of its life cycle, including during transport and storage. Packaging is a way of providing such protection. Packaging also forms an integral part of a product and may be a consumer's first point of contact with a brand. Thus apart from protecting the unit dose article from damage, the package must be aesthetically pleasing and provide space for branding and usage information to the consumer. In sum, the ideal package is functional, informative and attractive.

One attempt to meet these needs has been to package unit dose articles in flexible bags. To prevent waste and to provide a full looking bag, the bags are typically sized according to the volume of unit dose articles contained therein. The height of the bag is often manipulated to provide for a good shelf presence. Oftentimes, these considerations lead to a tall bag having a small footprint and consequently a high center of gravity. These bags tend to tip over on the store shelf.

Some bags have a window through which the consumer may see the product prior to purchase. The size and placement of the window is such that the bag appears to be full of product. A full looking bag has been viewed as a critical element for conveying to consumers that they are getting their money's worth.

Given these considerations, as well as that unit dose articles are sold in a variety of counts, the manufacturer may be required to make a whole series of bags for a single final product. This can be disadvantageous since it adds to manufacturing costs.

Thus there remains a need for an attractive bag that: protects unit dose articles from moisture; provides the consumer with brand and usage information, and that can be utilized to package a variety of article counts, while still signaling to the consumer that they are getting value for their money.

SUMMARY OF THE INVENTION

The present invention addresses the aforementioned needs. Rather than providing a series of bags of different sizes, a single sized flexible bag is used to package a variety of counts of unit dose articles. The bags can have a large footprint for stability. A transparent window is provided through which the consumer can see the fill line or “height” of varying counts contained within a single sized bag. “Transparent” as used herein means that the height of the unit dose articles is visible through the window. Consequently, “transparent” is used interchangeably with “translucent”. The present bag may also provide a “billboard space” on the front of a package so that the branding and use of the unit dose articles within can be clearly communicated to the consumer.

In some embodiments, the flexible bag contains a plurality of at least partially water soluble unit dose articles. The bag comprises a front panel and a back panel marginally joined thereto along at least two opposed edges such that they are in a confronting relationship to form a closed bag. The front panel and the back panel are joined at the top by a frangible seal and may optionally be additionally joined at the top with a resealable closure. “Frangible seal” as used herein means a seal that is capable of being broken. The bag also comprises a bottom panel that is intermediate to the front and back panels, and which is joined to each of the front and back panels. The front panel comprises at least one transparent window and at least one opaque portion. The unit dose articles are distributed from the bottom of the bag to a height therein. The bag provides an empty space above the height of the articles such that the transparent window of the front panel intercepts the unit dose articles and the empty space.

In some embodiments, the bag contains unit dose articles having a pincushion shape with a major dimension. The bag provides an empty space above the height of the unit dose articles. The transparent window of the front panel has a height taken in the vertical direction of the front panel that intercepts the unit dose articles and the empty space. The width of the transparent window may be greater than the major dimension of the unit dose articles at the height thereof.

In some embodiments, the unit dose article comprises a liquid laundry composition encapsulated in a film material that is at least partially soluble in water.

In some embodiments, the invention is directed to a method of providing a flexible sealed bag containing a plurality of unit dose articles. The method comprising the steps of: providing an open flexible bag comprising:

-   -   a front panel and a back panel marginally joined thereto along         at least two opposed edges to be in a confronting relationship         to form a closed bag; the front panel and the back panel being         joined at the top by a frangible seal;     -   a bottom panel intermediate to the front panel and the back         panel, and joined to each of the front panel and back panel;     -   wherein the front panel comprises at least one transparent         window and at least one opaque portion;         filling the bag with a plurality of at least partially water         soluble unit dose articles such that the articles are         distributed from the bottom of the bag to a height therein;         providing an empty space above the height of the articles,         whereby said transparent window of said front panel intercepts         said articles and said empty space; and sealing the bag.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming the invention, it is believed that the present invention will be better understood from the following description of preferred embodiments taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of a bag containing articles according to the present invention.

FIG. 1 a is a perspective view of a unit dose article according to the present invention.

FIG. 2 is a bottom view of the bag of FIG. 1.

FIGS. 3 a, 3 b, 3 c and 3 d are frontal views of alternative embodiments of bags containing articles according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The article of manufacture of the present invention is a flexible bag that contains a plurality of unit dose articles. The flexible bag may reduce and/or prevent exposure of the articles to moisture prior to and/or during transport and storage. The flexible bag may comprise a transparent window through which the consumer can see the fill line or “height” of the unit dose articles when the bag is displayed to the consumer for purchase at the point of purchase. Moreover, the flexible bag may provide a “billboard space” on the front of the bag so that indicia such as branding and usage instructions can be clearly communicated to the consumer.

The transparent window may have a constant or variable width. “Constant width” as used herein refers to a window having the same width throughout its vertical dimension. “Variable width” as used herein refers to a window having a width that differs in its vertical dimension.

FIGS. 1 and 2-3 d generally show flexible bags 10 containing a plurality of unit dose articles 100 per the present invention. Although the bags are as described and illustrated in the figures, they need not have these particular panel configurations provided that they comprise a compartment for the unit dose articles. For example, the bag could comprise gussets along the side. The bag could additionally comprise one or more side panels joined to the front panel and back panel. In a further example, the bag could additionally comprise internal partitions. Moreover, although the front panel of the bags as described and illustrated in figures is generally rectangular, it may take other suitable shapes. For example, the front panel could be generally circular.

The sealed flexible bag 10 as illustrated in FIG. 1 comprises a front panel 30, a back panel 50 and a bottom panel (not shown). The front panel 30 in this embodiment is rectangularly shaped and comprises spaced apart side edges 35 a, 35 b defining a width there between. The front panel is marginally joined to the back panel 50 along at least two opposed edges to be in confronting relationship. FIG. 1 shows the two opposed edges marginally joined together, those opposed edges of the front panel and back panel, respectively 35 a, 55 a. The bottom panel (not shown) is intermediate to the front panel 30 and back panel 50, and joined to each. The front panel 30 and the back panel 50 are joined at the top by a frangible seal 20.

A variety of materials can be used to form the panels of the bag, the seal(s) and other elements of the present invention. Technical requirements such as moisture protection and compatibility with product as well as costs and ease of manufacture are several factors to consider when selecting these materials.

One or more materials may be used to form one or more panels 30, 50 of a bag 10. In some embodiments, one or more panels 30, 50 comprise layers of material. In some embodiments, the layers are laminated together. Materials of use include, but are not limited to film forming plastics. Film forming plastics may be selected from the group of polyethylene terephthalate, polyethylene, Nylon™, Barex™, Evoh™ and combinations thereof. In some embodiments, the panels 30, 50 may comprise layers laminated together.

The panels 30, 50 of the bag 10 may be joined along the edges 35 a, 35 b using any suitable method that will provide a seal that serves as a moisture barrier. Non-limiting examples include ultrasonic welding, autogeneous bonding, pressure sealing, adhesive sealing and combinations thereof.

Any suitable means of creating a frangible seal joining the front and back panels together is of use. Non-limiting examples include perforating, applying a line of weakness, peelable seal, reasealable closures and combinations thereof.

As shown in FIG. 1, the front panel 30 comprises at least one opaque portion 31 and at least one transparent window 32. In some embodiments, the at least one opaque portion 31 may contain information including, but not limited to, instructions for use, advertising, performance information and the like. The transparent window 32 in this embodiment is variable in width, i.e., it diverges to become wider as the bottom of the bag 10 is approached.

The articles 100 are distributed from the bottom of the bag 10 to a height 110 therein, providing an empty space 33 above the height 110 of the unit dose articles 100 such that the transparent window 32 intercepts the articles 100 and the empty space 33. The flexible bag 10 shown in FIG. 1 comprises an optional, additional closure 25 for securing the bag 10 in a closed condition after the frangible seal 20 is broken.

FIG. 1 a shows an exemplary unit dose article 100 of the present invention. The unit dose article 100 is preferably a unitized dose of a household care composition including, but not limited to laundry, dish or hard surface cleaning compositions. While such articles 100 can have a variety of forms, shapes and compositions, a common feature of such additives is their susceptibility to being degraded, deactivated, rendered unstable or dissolved when exposed to prolonged and/or high levels of moisture. By way of example, laundry additives encapsulated in polymer films that are designed to be fast dissolving under both hot and cold water conditions, may become tacky, unstable and even prematurely dissolved if not protected from prolonged exposure to atmospheric moisture. Such articles are described in U.S. Patent Publication No. 2010/0192986A1 and U.S. Pat. No. 6,995,126, which are incorporated herein by reference.

As shown in FIG. 1 a, the unit dose article may have a pincushion shape with a major dimension 101 along one side. As used herein, “major dimension” defines the largest linear dimension of the unit dose article 100. If the unit dose article 100 is substantially circular, the “major dimension” defines the diameter thereof. In embodiments in which the bag 10 contains a plurality of unit dose articles 100 having different shapes and sizes, the major dimension 101 corresponds to the major dimension of the largest of the unit dose article 100.

FIG. 2 is a bottom view of the bag 10 containing articles 100 of FIG. 1. In this embodiment, the bottom panel 40 of the bag is transparent such that at least a portion of the articles 100 contained therein are visible there through. The bottom panel 40 is intermediate to and joins the front panel 30 and the back panel 50. The front panel 30 is marginally joined to the back panel 50 along two sets of opposed edges in confronting relationship. FIG. 2 shows a first set of opposing edges as 35 a and 55 a and a second set of opposing edges as 35 b and 55 b.

FIGS. 3 a-3 d are frontal views of alternative embodiments of flexible bags 10 containing articles 100 according to the present invention. FIG. 3 a shows an embodiment of a flexible bag 10 containing a plurality of articles 100 having different sizes and shapes. The transparent window 32 in the front panel 30 of the bag 10 diverges to have a maximum width of the window at the height 110 of the articles 100 in the bag 10 when the bag is displayed to the consumer for purchase at the point of purchase.

FIG. 3 b shows an embodiment of a flexible bag 10 containing a plurality of articles 100 having substantially the same shape and size. The transparent window 32 in the front panel 30 of the bag 10 has a major axis 320. The major axis 320 is diagonally oriented relative to the rectangularly shaped front panel 30.

FIG. 3 c shows an embodiment of a flexible bag 10 containing a plurality of articles 100 optionally having substantially the same shape and size. Two transparent windows, a top window 32 a and a bottom window 32 b are in the front panel 30 of the bag 10. The top transparent window 32 a intercepts the articles 100 and the empty space 33.

FIG. 3 d shows an embodiment of a flexible bag 10 containing a plurality of articles 100 optionally having substantially the same shape and size. Three transparent windows, 32 a, 32 b and 32 c are in the front panel 30 of the bag 10. One transparent window 32 a intercepts the articles 100 and the empty space 33. The transparent windows 32 b and 32 c are below the height 110 of the articles.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. 

What is claimed is:
 1. A flexible sealed bag containing a plurality of at least partially water soluble unit dose articles, said bag comprising: a front panel and a back panel marginally joined thereto along at least two opposed edges to be in a confronting relationship to form a closed bag, said front panel and said back panel being joined at the top by a frangible seal; a bottom panel intermediate said front panel and said back panel, and joined to each of said front panel and back panel; wherein said front panel comprises at least one transparent window and at least one opaque portion, and said articles are distributed from the bottom of said bag to a height therein, providing an empty space above the height of said articles, whereby said transparent window of said front panel intercepts said articles and said empty space.
 2. The flexible bag containing a plurality of articles according to claim 1, wherein said articles are of substantially equal size and shape.
 3. The flexible bag containing a plurality of articles according to claim 2, wherein said articles comprise unit doses of a liquid laundry composition.
 4. The flexible bag containing a plurality of articles according to claim 1, wherein said bag comprises a polymeric film throughout, and said front panel of said bag is generally rectangularly shaped and comprises spaced apart side edges defining a width there between, said side edges of said front panel being heat sealed to corresponding side edges of said back panel.
 5. The flexible bag containing a plurality of articles according to claim 4, wherein said at least one transparent window has a variable width.
 6. The flexible bag containing a plurality of articles according to claim 5, wherein said window diverges to become wider as the bottom of said bag is approached.
 7. The flexible bag containing a plurality of articles according to claim 5, wherein said window diverges to have a maximum width at the height of said articles in said bag.
 8. The flexible bag containing a plurality of articles according to claim 6, wherein said window has a major axis, said major axis being diagonally oriented relative to said rectangularly shaped front panel.
 9. A flexible sealed bag containing a plurality of unit dose articles, said bag comprising: a front panel and a back panel marginally joined thereto along at least two opposed edges to be in a confronting relationship and form a closed bag, said front panel and said back panel being joined at the top by a frangible seal, said unit dose articles being distributed from the bottom of said bag to a height therein; a bottom panel intermediate said front panel and said back panel, said bottom panel being joined to each of said front panel and said back panel; wherein said front panel comprises at least one transparent window and at least one opaque portion, and, providing an empty space above the height of said articles, said articles having a pincushion shape with a major dimension along one side; whereby said transparent window of said front panel intercepts said articles and said empty space, said transparent window having a width taken in the horizontal direction, said width being greater than said major dimension of said articles.
 10. The flexible closed bag containing a plurality of unit dose articles according to claim 9, comprising a plurality of vertically disposed windows, with at least one window being below the height of said articles.
 11. The flexible sealed bag containing a plurality of unit dose articles according to claim 9, wherein said window is diagonally oriented and monotonically increases in width as the bottom of said bag is approached.
 12. The flexible sealed bag containing a plurality of unit dose articles according to claim 10, wherein said window intercepts the bottom of said bag, said window having a width greater at the bottom of said bag than said major dimension of said articles.
 13. The flexible sealed bag containing a plurality of unit dose articles according to claim 9, wherein said articles comprise a plurality of different sizes, said major dimension of said articles corresponding to the major dimension of the largest size of said articles.
 14. The flexible sealed bag containing a plurality of unit dose articles according to claim 9 wherein said bottom of said bag has at least one gusset therein.
 15. The flexible sealed bag containing a plurality of unit dose articles according to claim 14 wherein said bottom of said bag is transparent.
 16. The flexible sealed bag containing a plurality of unit dose articles according to claim 15 wherein said front panel has a first thickness and said bottom panel has a second thickness, said thickness of said bottom panel being different from said thickness of said front panel.
 17. The flexible sealed bag containing a plurality of unit dose articles according to claim 9 wherein said front panel has a surface area and said opaque portion of said front panel comprises at least about 20% percent of said surface area.
 18. The flexible sealed bag containing a plurality of unit dose articles according to claim 9 wherein said transparent window comprises indicia.
 19. A method of providing a flexible sealed bag containing a plurality of unit dose articles, said method comprising the steps of: (a) providing an open flexible bag comprising: a front panel and a back panel marginally joined thereto along at least two opposed edges to be in a confronting relationship to form a closed bag, said front panel and said back panel being joined at the top by a frangible seal; a bottom panel intermediate said front panel and said back panel, and joined to each of said front panel and back panel; wherein said front panel comprises at least one transparent window and at least one opaque portion; (b) filling said bag with a plurality of at least partially water soluble unit dose articles such that said articles are distributed from the bottom of said bag to a height therein; (c) providing an empty space above the height of said articles, whereby said transparent window of said front panel intercepts said articles and said empty space; and. (d) sealing said bag.
 20. The method of claim 19, further comprising the step of displaying said flexible sealed bag for purchase by a consumer at a point of purchase. 